Manufacturing method of ultralow-energy-consumption sandwich thermal insulation external wall panel with impact resistance

Abstract

The invention relates to the field of buildings, in particular to a manufacturing method of an ultralow-energy-consumption sandwich thermal insulation external wall panel with impact resistance, which comprises the following steps: S1, designing a wall panel, and determining the thicknesses of a concrete outer acanthus, a concrete inner acanthus and a thermal insulation layer; s2, according to the requirement that the two ends of the tie cylinder need to be inserted into the concrete outer acanthus and the concrete inner pressing plate, the size of the tie cylinder is designed, whether the anti-impact energy absorption capacity and the initial rigidity of the wallboard meet the design requirement or not is calculated, and after the requirement is met, the tie cylinder of the corresponding size is machined; s3, connecting the tie barrels to form a honeycomb structure, and forming positioning holes corresponding to the diameters of the transverse steel bars in the tie barrels; s4, a groove is formed in the middle of the heat preservation layer, the groove is matched with the honeycomb structure formed by the tie barrels in a clamped mode, regular hexagonal layer pieces corresponding to the cross section size of the inner wall of each tie barrel are formed after the heat preservation layer stripped during grooving is cut, the number of the regular hexagonal layer pieces corresponds to the number of the tie barrels, each regular hexagonal layer piece is pasted to the inner wall of the corresponding tie barrel, and the regular hexagonal layer pieces and the inner wall of the corresponding tie barrel are sealed; the pulling barrel and the heat preservation layer form an integral structure; and S5, the heat preservation layer where the tie barrels are pre-fixed, the transverse steel bars and the longitudinal steel bars are fixed into the concrete pouring mold, all the transverse steel bars penetrate through the positioning holes of the corresponding tie barrels, concrete is poured into the concrete pouring mold, then curing and demolding are conducted, and manufacturing of the wallboard is completed. The thermal insulation performance is improved, and meanwhile the initial rigidity and impact resistance of the wallboard are improved.

Description

Technical Field

[0001] The present invention relates to the field of construction, and in particular to a method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance. Background Art

[0002] Traditional building wall panels and floor slabs are typically made of solid reinforced concrete slabs. However, due to their poor thermal insulation, buildings using solid reinforced concrete slabs often experience significant energy losses. To improve the thermal insulation of buildings, precast concrete sandwich panels have emerged. These panels primarily consist of two concrete blades, an insulation layer in the middle, and anchors connecting the two concrete blades. The anchors are key components connecting the two concrete blades, and their shear force transmission capacity significantly impacts the overall performance of the precast concrete sandwich panels.

[0003] Conventional precast concrete sandwich wall panels typically use concrete blocks or steel bars as anchors. While these precast concrete sandwich wall panels can achieve high overall performance, they can also produce significant thermal bridging, which reduces the panels' thermal insulation. To address the impact of thermal bridging, extruded polystyrene (XPS) has been used as an insulation layer, along with GFRP plate anchors, to replace traditional concrete blocks or steel bars to improve the panels' thermal insulation. However, this structural form, while improving thermal insulation performance, often reduces the panel's initial stiffness and impact resistance, creating a trade-off between the two, and thus urgently needs to be addressed. Summary of the Invention

[0004] To avoid and overcome the technical problems existing in the prior art, the present invention provides a method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance. The present invention improves the initial stiffness and impact resistance of the wall panel while improving the thermal insulation performance.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance comprises the following steps:

[0007] S1. Design the wall panels and determine the thickness of the concrete outer blade, concrete inner blade and insulation layer;

[0008] S2. Design the dimensions of the tie tubes, assuming both ends of the tie tubes must be inserted into the concrete outer blades and the concrete inner pressure plate. Calculate whether the wall panel's impact energy absorption and initial stiffness meet the design requirements. If they meet the requirements, process the tie tubes of corresponding dimensions.

[0009] S3, connecting the tie tubes to form a honeycomb structure, and providing positioning holes on each tie tube corresponding to the diameter of the transverse steel bars;

[0010] S4. Cut a groove in the middle of the insulation layer to engage with the honeycomb structure formed by the tie tube. Cut the insulation layer that is peeled off during the groove to form regular hexagonal layers corresponding to the cross-sectional dimensions of the inner wall of each tie tube. The number of regular hexagonal layers corresponds to the number of tie tubes. Glue each regular hexagonal layer to the inner wall of the corresponding tie tube to form an integral structure with the tie tube and the insulation layer.

[0011] S5. Fix the insulation layer, transverse reinforcement and longitudinal reinforcement with pre-fixed tie tubes in the concrete casting mold, make each transverse reinforcement pass through the positioning hole of the corresponding tie tube, pour concrete into the concrete casting mold, and then perform curing and demoulding to complete the manufacture of the wall panel.

[0012] As a further embodiment of the present invention:

[0013]

[0014] Among them, K L is the initial stiffness of the wall panel;

[0015] E L Absorb energy for the wall panels’ impact resistance;

[0016] B is the side length of the cross section of the tie tube;

[0017] H L is the length of the tie tube.

[0018] As a further solution of the present invention: the cross section of the tie tube is in the form of a regular hexagon, the tube body of each tie tube forms a honeycomb layout along the direction perpendicular to the wall panel surface, and the tie tube is made of the same material as the insulation layer.

[0019] As a further solution of the present invention: a steel mesh is provided in both the concrete outer blade plate and the concrete inner blade plate, the steel mesh includes transverse steel bars provided adjacent to the insulation layer and longitudinal steel bars provided away from the insulation layer, and there is a spacing between the transverse steel bars and the longitudinal steel bars.

[0020] As a further solution of the present invention: the diameter of the positioning hole is 6 mm to 10 mm.

[0021] As a further solution of the present invention, the two oppositely arranged sections of the tie tube wall are respectively arranged parallel to the two side surfaces of the wall panel.

[0022] As a further solution of the present invention: the tie tube and the insulation layer are both extruded polystyrene boards.

[0023] As a further solution of the present invention: the concrete outer blade plate and the concrete inner blade plate are both filled with rubber aggregate, and the particle size of the rubber aggregate is 10 mm to 19 mm.

[0024] As a further solution of the present invention: the wall thickness of the tie tube is 1mm to 3mm, the side length of the cross section of the tie tube is 60mm to 120mm; and the thickness of the thermal insulation layer is 50mm to 100mm.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] 1. The present invention provides a honeycomb structure for the tie members, which are fixedly connected to the insulation layer to form a whole, so that both ends of the tie tube extend into the inner concrete blade and the outer concrete blade. This improves the insulation performance while making the wall panel have better impact resistance and higher initial stiffness.

[0027] 2. The present invention further improves the energy absorption capacity of the wall panel by adding rubber aggregate into the concrete blade, increases the toughness of the concrete, improves the brittleness of the concrete, and further improves the impact resistance of the wall panel.

[0028] 3. The present invention provides a theoretical basis for practical engineering applications by calculating and predicting the initial stiffness and impact energy absorption of the wallboard. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 It is a structural schematic diagram of the present invention.

[0030] In the picture:

[0031] 1. Concrete outer blade; 2. Insulation layer; 3. Concrete inner blade;

[0032] 4. Tie tube; 41. Positioning hole; 51. Transverse reinforcement; 52. Longitudinal reinforcement. DETAILED DESCRIPTION

[0033] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0034] See also Figure 1In an embodiment of the present invention, a method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance is provided, wherein the wall panel includes a concrete outer blade 1 and a concrete inner blade 3 located on both sides of the insulation layer 2. A steel mesh is provided in the concrete outer blade 1 and the concrete inner blade 3, and the steel mesh includes a transverse steel bar 51 and a longitudinal steel bar 52. The transverse steel bar 51 is arranged adjacent to the insulation layer 2, and the longitudinal steel bar 52 is arranged away from the insulation layer 2. There is a distance between the transverse steel bar 51 and the longitudinal steel bar 52, and they are tied and fixed at the nodes. When pouring the concrete outer blade 1 and the concrete inner blade 3, rubber aggregate needs to be added, and the particle size of the rubber aggregate is controlled to be 10mm to 19mm.

[0035] The heat-insulating layer 2 is provided with an integral tie tube 4 , and a plurality of tie tubes 4 are provided. The tie tubes 4 are constructed in the form of a regular hexagon. The tie tubes 4 are connected to form a honeycomb structure, and adjacent tie tubes 4 share a common tube wall.

[0036] The length of the tie tube 4 is greater than the thickness of the insulation layer 2. When the tie tube 4 is fixed to the insulation layer 2, the geometric center of the tie tube 4 is located in the same plane as the geometric center of the insulation layer 2. The overall thickness of the insulation layer 2 is controlled to be 50mm to 100mm.

[0037] The insulation layer 2 and the tie tube 4 are made of the same material: extruded polystyrene. The insulation layer 2 and tie tube 4 are integrated. To secure them, the insulation layer 2 is first cut to form a ring-shaped structure that wraps around the outer ring of the honeycomb structure of the tie tube 4, forming a plug-in fit with the honeycomb structure. After insertion, the structure is bonded and secured. The cut sheet material from the insulation layer 2 is then processed to form regular hexagonal layers that correspond to the inner dimensions of the tie tube 4. Each layer is located at the same height as the annular structure of the insulation layer 2, forming a split insulation layer 2 that is bonded and secured to the wall of the tie tube 4.

[0038] The thickness of the tie tube 4 is set to 1 mm to 3 mm, and the side length of the cross section of the tie tube 4 needs to be controlled to be 60 mm to 120 mm.

[0039] The tie tube 4 located in the concrete outer blade 1 and the concrete inner blade 3 is provided with positioning holes 41 for the transverse steel bars 51 in the concrete outer blade 1 and the concrete inner blade 3 to pass through. The aperture of the positioning hole 41 corresponds to the diameter of the transverse steel bar 51, and the aperture of the positioning hole 41 is 6mm~10mm.

[0040] The honeycomb structure formed by the tie tube 4 must be located within the outer edge of the insulation layer 2 to avoid interference with the edge of the insulation layer 2, and should be placed as close to the center of the insulation layer 2 as possible. After the tie tube 4 is fixed, it is necessary to ensure that the two opposing tube wall sections are parallel to the side of the wall panel.

[0041] The following steps are involved in the manufacture of wall panels:

[0042] S1. Design the wall panels and determine the thickness of the concrete outer blade 1, the concrete inner blade 3, and the insulation layer 2;

[0043] S2. Design the dimensions of the tie tube 4, with both ends of the tie tube 4 inserted into the concrete outer blade 1 and the concrete inner pressure plate 3. Calculate whether the impact energy absorption and initial stiffness of the wall panel meet the design requirements. If they meet the requirements, process the tie tube 4 of the corresponding size.

[0044]

[0045] Among them, K L is the initial stiffness of the wall panel;

[0046] E L Absorb energy for the wall panels’ impact resistance;

[0047] B is the side length of the cross section of the tie tube 4;

[0048] H L is the length of the tie tube 4.

[0049] S3, connecting the tie tubes 4 to form a honeycomb structure, and forming a positioning hole 41 corresponding to the diameter of the transverse steel bar 51 on each tie tube 4;

[0050] S4. Cut a groove in the middle of the insulation layer 2 to engage with the honeycomb structure formed by the tie tubes 4. Cut the insulation layer 2 peeled off during the groove cutting to form regular hexagonal layers corresponding to the cross-sectional dimensions of the inner walls of the tie tubes 4. The number of regular hexagonal layers corresponds to the number of tie tubes 4. Glue each regular hexagonal layer to the inner wall of the corresponding tie tube 4 so that the tie tube 4 and the insulation layer 2 form an integral structure.

[0051] The thermal insulation layer 2 and the tie tube 4 are pre-bonded and fixed by glue. After the concrete is poured, the solidified concrete will clamp the tie tube 4.

[0052] S5. Fix the insulation layer 2, transverse steel bars 51 and longitudinal steel bars 52 with pre-fixed tie tubes 4 in the concrete casting mold, make each transverse steel bar 51 pass through the positioning hole 41 of the corresponding tie tube 4, pour concrete into the concrete casting mold, and then perform curing and demoulding to complete the manufacture of the wall panel.

[0053] During the actual pouring process, the blades on one side of the insulation layer 2 are poured first, then the wall panel is flipped 180 degrees and the blades on the other side are poured. Positioning holes 41 can be drilled after the insulation layer 2 is secured in the concrete casting mold. When pouring the concrete blades on the corresponding side, positioning holes 41 are opened on the corresponding side of the tie tube 4.

[0054] In this embodiment, when the wall panel is used as a building curtain wall, the thickness of the concrete outer blade 1 is set to 60 mm, the thickness of the insulation layer 2 is set to 30 mm, and the thickness of the concrete inner blade 3 is set to 200 mm.

[0055] A numerical model of the wall panel was constructed using LS-DYNA software, with the concrete blades, insulation layer, and tie tubes all constructed using 3D solid models. The thickness of the concrete outer blade 1 and the concrete inner blade 3 was 60 mm, and the length and width were 1200 mm. The thickness of the insulation layer 2 was 50 mm, and the overall thickness of the wall panel was 170 mm. A cylindrical drop weight with a diameter of 200 mm and a mass of 100 kg was constructed and configured as a rigid body. The contact velocity between the drop weight and the center of the wall panel surface was set to 6.62 m / s.

[0056] In the analysis, the cross-sectional side length B of the tie tube 4 is set to five working conditions, with side lengths of 60mm, 75mm, 90mm, 105mm and 120mm respectively. L Five working conditions were set, with lengths of 90mm, 100mm, 110mm, 120mm, and 130mm. The corresponding depths D of the two ends of the tie tube 4 extending into the concrete blade were 20mm, 25mm, 30mm, 35mm, and 40mm. The impact energy absorption values obtained through simulation analysis and the calculated impact energy absorption values for different size combinations are shown in Table 1 below. model It represents the impact absorption energy of the wall panel obtained by software simulation, E L It is the calculated impact absorption energy of the wall panel.

[0057] Table 1

[0058] serial number B(mm) D(mm) <![CDATA[E model (J)]]> <![CDATA[E L (J)]]> <![CDATA[E model / AND L ]]> 60-90 60 20 1075.02 1118.03 0.9615 60-100 60 25 1169.41 1153.53 1.0138 60-110 60 30 1226.75 1228.76 0.9984 60-120 60 35 1074.64 1068.55 1.0057 60-130 60 40 962.11 929.152 1.0355 75-90 75 20 1063.64 1006.47 1.0568 75-100 75 25 1106.94 1052.85 1.0514 75-110 75 30 1130.80 1147.73 0.9853 75-120 75 35 971.31 1015.91 0.9561 75-130 75 40 885.60 913.68 0.9693 90-90 90 20 1098.79 1107.33 0.9923 90-100 90 25 1161.58 1154.02 1.0066 90-110 90 30 1281.94 1257.96 1.0191 90-120 90 35 1162.95 1143.98 1.0166 90-130 90 40 1073.24 1068.33 1.0046 105-90 105 20 1092.85 1109.62 0.9849 105-100 105 25 1096.02 1146.05 0.9563 105-110 105 30 1286.99 1248.48 1.0308 105-120 105 35 1206.30 1141.74 1.0565 105-130 105 40 1133.33 1082.11 1.0473 120-90 120 20 1104.42 1047.18 1.0547 120-100 120 25 1095.47 1062.77 1.0308 120-110 120 30 1178.32 1153.12 1.0219 120-120 120 35 1068.85 1043.06 1.0247 120-130 120 40 993.26 988.87 1.0044

[0059] It can be seen that the impact energy absorption data of the wall panels obtained by simulation is relatively consistent with the calculated data. The impact resistance of the wall panels can be better predicted through calculation.

[0060] Under the same size combination, the initial stiffness of the wall panel obtained by simulation analysis and the initial stiffness of the wall panel calculated are shown in Table 2 below. model Indicates the initial stiffness of the wall panel obtained by software simulation, K L is the calculated initial stiffness of the wall panel.

[0061] Table 2

[0062] serial number D(mm) B(mm) <![CDATA[K model (kN / mm)]]> <![CDATA[K L (kN / mm)]]> <![CDATA[K model / K L ]]> 60-90 20 60 2242.77 2216.93 1.0117 60-100 20 75 2076.56 2000.19 1.0382 60-110 20 90 1762.09 1702.29 1.0351 60-120 20 105 1860.82 1841.80 1.0103 60-130 20 120 1878.63 1811.80 1.0369 75-90 25 60 2201.29 2177.87 1.0108 75-100 25 75 2063.59 1990.68 1.0366 75-110 25 90 1701.88 1726.83 0.9855 75-120 25 105 1923.41 1904.88 1.0097 75-130 25 120 1968.72 1917.93 1.0265 90-90 30 60 2155.99 2105.61 1.0239 90-100 30 75 1818.87 1923.37 0.9457 90-110 30 90 1701.88 1668.97 1.0197 90-120 30 105 1927.11 1860.98 1.0355 90-130 30 120 1870.24 1892.48 0.9882 105-90 35 60 2247.491 2288.27 0.9821 105-100 35 75 2084.4 2086.38 0.9990 105-110 35 90 1828.23 1816.83 1.0063 105-120 35 105 1965.17 1998.18 0.9835 105-130 35 120 1981.065 2023.53 0.9790 120-90 40 60 2455.88 2494.02 0.9847 120-100 40 75 2212.11 2247.88 0.9840 120-110 40 90 1862.26 1938.58 0.9606 120-120 40 105 2020.95 2084.69 0.9684 120-130 40 120 2044.87 2079.29 0.9835

[0063] It can be seen that the initial stiffness of the wall panel obtained by simulation is relatively consistent with the initial stiffness data of the wall panel obtained by calculation. The initial stiffness parameters of the wall panel can be well predicted through calculation.

[0064] While maintaining the same thickness as the concrete outer blade 1, concrete inner blade 3, and insulation layer 2, the tie tube 4 was replaced with existing GFRP plate-type anchors. The depth of the GFRP plate-type anchors extending into the concrete outer blade 1 and concrete inner blade 3 was consistent with the depth of the tie tube 4. The GFRP plate-type anchors were densely distributed, with a spacing of 125 mm.

[0065] The initial stiffness obtained is 1330.09 KN / mm, which is obviously lower than the initial stiffness obtained by the simulation of the wall panels of this application. The impact absorption energy is 661.387 J, which is also lower than the impact absorption energy obtained by the simulation of the wall panels of this application. The comprehensive performance of this application is much higher than that of the traditional prefabricated wall panels using GFRP plate anchors.

[0066] The basic principles of the present application have been described above in conjunction with specific embodiments. However, it should be noted that the advantages, strengths, and effects mentioned in this application are merely illustrative and not restrictive, and it should not be assumed that these advantages, strengths, and effects are required of each embodiment of this application. In addition, the specific details disclosed above are merely illustrative and facilitating understanding, and are not restrictive. The above details do not limit this application to necessarily being implemented using the above specific details.

[0067] The block diagrams of the devices, devices, equipment, and systems involved in this application are merely illustrative examples and are not intended to require or imply that they must be connected, arranged, or configured in the manner shown in the block diagrams. As will be appreciated by those skilled in the art, these devices, devices, equipment, and systems can be connected, arranged, or configured in any manner. Words such as "include," "comprise," "have," and the like are open-ended words, meaning "including but not limited to," and can be used interchangeably therewith. The words "or" and "and" used herein refer to the words "and / or" and can be used interchangeably therewith, unless the context clearly indicates otherwise. The word "such as" used herein refers to the phrase "such as but not limited to," and can be used interchangeably therewith.

Claims

1. A method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance, characterized in that: The steps include: S1. Design the wall panels and determine the thickness of the concrete outer blade (1), the concrete inner blade (3) and the insulation layer (2); S2. Design the size of the tie tube (4) with the requirement that both ends of the tie tube (4) must be inserted into the concrete outer blade (1) and the concrete inner pressure plate (3). Calculate whether the impact energy absorption and initial stiffness of the wall panel meet the design requirements. If they meet the requirements, process the tie tube (4) of the corresponding size. S3, connecting the tie tubes (4) to form a honeycomb structure, and providing a positioning hole (41) corresponding to the diameter of the transverse steel bar (51) on each tie tube (4); S4. A groove is made in the middle of the thermal insulation layer (2) to engage with the honeycomb structure formed by the tie tube (4). The thermal insulation layer (2) peeled off during the groove is cut to form regular hexagonal layers corresponding to the cross-sectional dimensions of the inner wall of each tie tube (4). The number of regular hexagonal layers corresponds to the number of tie tubes (4). Each regular hexagonal layer is pasted to the inner wall of the corresponding tie tube (4) so that the tie tube (4) and the thermal insulation layer (2) form an integral structure. S5. Fix the insulation layer (2) pre-fixed with the tie tube (4), the transverse steel bars (51) and the longitudinal steel bars (52) in the concrete casting mold, make each transverse steel bar (51) pass through the positioning hole (41) of the corresponding tie tube (4), pour concrete into the concrete casting mold, and then perform curing and demoulding to complete the manufacture of the wall panel.

2. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1, characterized in that: Among them, K L is the initial stiffness of the wall panel; E L Absorb energy for the wall panels’ impact resistance; B is the side length of the cross section of the tie tube (4); H L is the length of the tie tube (4).

3. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: The cross section of the tie tube (4) is in the form of a regular hexagon, and the tube body of each tie tube (4) forms a honeycomb layout along the direction perpendicular to the wall panel surface. The tie tube (4) and the insulation layer (2) are made of the same material.

4. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: A steel mesh is provided in both the concrete outer blade (1) and the concrete inner blade (3), wherein the steel mesh includes transverse steel bars (51) provided adjacent to the thermal insulation layer (2) and longitudinal steel bars (52) provided away from the thermal insulation layer (2), and a spacing exists between the transverse steel bars (51) and the longitudinal steel bars (52).

5. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: The aperture of the positioning hole (41) is 6 mm to 10 mm.

6. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: The two oppositely arranged sections of the wall of the tie tube (4) are respectively arranged parallel to the two side surfaces of the wall panel.

7. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: The tie tube (4) and the thermal insulation layer (2) are both extruded polystyrene boards.

8. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: The concrete outer blade plate (1) and the concrete inner blade plate (3) are both filled with rubber aggregate, and the particle size of the rubber aggregate is 10 mm to 19 mm.

9. The method for manufacturing an ultra-low energy consumption sandwich insulation exterior wall panel with impact resistance according to claim 1 or 2, characterized in that: The wall thickness of the tie tube (4) is 1mm to 3mm, the side length of the cross section of the tie tube (4) is 60mm to 120mm; and the thickness of the heat-insulating layer is 50mm to 100mm.

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